Paint, Resin & Polymer Compounding worked example

Batch Scale-Up Risk with scale-up severity score of 3 score: a worked example

Here is what the math looks like when conditions slip. We hold every other input steady and drop scale-up severity score to 3 score, then walk the calculation through step by step. Score the risk of scaling a paint or resin batch from lab to production using severity, occurrence likelihood, and detection difficulty.

The inputs for this scenario

  • Scale-up severity score: 3 score (the input this scenario stresses; the baseline uses 6)
  • Occurrence likelihood score: 4 score (held at the documented default)
  • Detection difficulty score: 3 score (held at the documented default)

Working through the calculation

  • The calculation starts from the formula this tool documents: Batch scale-up risk score = severity * 0.4 + occurrence likelihood * 0.35 + detection difficulty * 0.25.
  • Batch scale-up risk score works out to 3.35 score at these inputs, and this is the headline figure for the scenario.
  • Scale-up severity score works out to 3 score at these inputs.
  • Occurrence likelihood score works out to 4 score at these inputs.
  • Detection difficulty score works out to 3 score at these inputs.

How this compares with the baseline

  • Against the tool's baseline example, where scale-up severity score sits at 6 score and the headline result is 4.55 score, this scenario comes in 26.37% below the baseline at 3.35 score.
  • The practical read: the gap between this scenario and the baseline is entirely attributable to scale-up severity score, so recovering it is worth quantifying in dollars before considering equipment or staffing changes. Scores are subjective inputs; the number is only meaningful if the same team uses a consistent scale across every batch it compares.

Results at a glance

  • Batch scale-up risk score: 3.35 score (headline result)
  • Scale-up severity score: 3 score
  • Occurrence likelihood score: 4 score
  • Detection difficulty score: 3 score

Run it with your numbers

  • To rerun this with your own numbers, open the live Batch Scale-Up Risk calculator, set scale-up severity score to your actual value, and adjust the remaining inputs to match your operation.

Last reviewed 2026-05-12.